Fiberboard container for packaging an article

ABSTRACT

Fiberboard containers for packaging flanged articles, such as sinks, having tubular body sections of appropriate depth. End closures are formed by four flaps which extend into the opening and portions of which overlie the end of the flange. At least one of the flaps abuts the outer wall of the bowl portion of the sink and holds it stable. The closures are completed without the need of adhesive or ancillary fasteners.

United States Patent [191 Dlugopolski [451 Feb. 18, 1975 1 FIBERBOARD CONTAINER FOR PACKAGING AN ARTICLE [75] Inventor: Joseph J. Dlugopolski, Lombard, Ill.

[73] Assignee: Inland Container Corporation,

Indianapolis, Ind.

[22] Filed: Dec. 18, 1972 {21] Appl. No.: 316,110

[52] US. Cl..l 206/45.l4, 206/521, 206/321,

229/34 HW [51] Int. Cl B65d 25/10 [58] Field of Search 206/45.14, 45.32, 46 R,

206/46 FR, 46 F, 46 H, 46 EN, 65 R, 65 C; 229/14 C, 37 E, 39 R, 40, 34 HW [56] References Cited UNITED STATES PATENTS 3,133,633 5/1964 Redmond 206/56 H 3,521,812 7/1970 Moers et al. 229/14 C X 3,604,560 9/1971 Farquhar 229/14 C X 3,618,848 11/1971 Pawlowski 206/45.l4 X 3,757,935 9/1973 Coons et a1. 206/46 H FOREIGN PATENTS OR APPLICATIONS 816,545 7/1969 Canada 206/46 FR Primary Examiner-William 1. Price Assistant Examiner-Douglas B. Farrow Attorney, Agent, or Firm-Fitch, Ever, Tabin & Luedeka 57 ABSTRACT Fiberboard containers for packaging flanged articles, such as sinks, having tubular body sections of appropriate depth. End closures are formed by four flaps which extend into the opening and portions of which overlie the end of the flange. At least one of the flaps abuts the outer wall of the bowl portion of the sink and holds it stable. The closures are completed without the need of adhesive or ancillary fasteners,

10 Claims, 5 Drawing Figures P FEBIBIQ ,7 SHEETIUFZ FIBERBOARD CONTAINER FOR PACKAGING AN ARTICLE This invention relates to shipping containers and more particularly to containers for packaging articles having a comparatively flat flange, for example, a sink. Whereas corrugated fiberboard containers provide a satisfactory and economical way for packaging items such as sinks or the like for shipment, heretofore such packages have employed several individual pieces or packing forms in order to locate and cushion the sink within the container. Usually, a container of rectangular cross-section has been employed which is proportioned to receive the generally rectangular perimeter flange of the sink and which has a depth such as to accommodate the bowl portion of the sink. The sink is first assembled with die-cut corner posts and/or end supports and is then inserted into the outer container. Similar packing arrangements have been used for packaging other such articles, for example, window fans, which likewise have a flange which defines one surface of the article. More efficient containers for packaging such flanged articles are desired.

It is an object of the present invention to provide an improved container for packaging a flanged article. Another object of the invention is to provide a container for securely packaging a flanged article for shipment, which container is fabricated from a one-piece blank of corrugated board. A further object is to provide an improved package for shipping a sink or the like which utilizes a corrugated fiberboard container.

These and other objects of the invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view illustrating a partially formed container having various features of the invention illustrated with one end closure shown in the open position;

FIG. 2 is a plan view of a major portion of the blank from which the container illustrated in FIG. 1 is formed;

FIGS. 3 and 4 are views which are similar to FIG. 1 but show a sink disposed within the container and depict the end closure in sequential stages of completion; and

- FIG. 5 shows the container of FIG. 1, with the end closure completed.

The invention provides a container 11 for packaging an article having a peripheral flange which defines one surface thereof. FIGS. 3-5 illustrate the packaging of a sink 13 having a flat peripheral flange 15 of generally rectangular shape from which a single or double bowl portion depends. The bowl portion is defined by walls which extend transversely to the flange and include at least two end walls 17 and at least two lateral walls 19. Although the invention is illustrated with regard to packaging a sink, it should be understood that containers employing this constructional concept can be likewise advantageously used for packaging other articles having one surface defined by a flange and having a body portion extending in a transverse direction from that flange, for example, a window fan.

Depicted in FIG. 2 is the major portion of a corrugated fiberboard blank 21 from which the container 11 illustrated in FIG. 1 is formed. In many instances, the article being packaged will be symmetrical, and in such a case, the end closures at both ends of the container will be mirror images of each other. For this reason, only slightly more than one-half of the. blank 21 showing the closure at one end of the container is illustrated in FIG. 2. However, depending upon the construction of the article being packaged, it should be understood that the closure at each end of the container 11 could be proportioned differently. Moreover, if the article being packaged was not symmetrical, and particularly if the article did not require cushioning, any suitable type of end closure could be employed, for example, one formed by a plurality of glued flaps.

The illustrated container 11 includes a body section of rectangular cross-section formed by a top panel 23, a bottom panel 25 and a pair of side panels 27,29'which are perpendicular thereto. For ease of reference, the uppermost panel 23 in FIG. 1 is referred to as the top panel and the lowermost panel 25 as the bottom panel, though the sink 13 is disposed upsidedown in the container 11 so that the upper surface of the flange 15 of the sink lies flush upon the interior surface of the bottom panel 25.

The illustrated blank 21 is provided with three parallel score lines 31 which run longitudinally thereof and which define the common edges between the top, bottom and side panels. A transverse score line 33 defines the end of the body section and the beginning of the end closure. The illustrated blank 21 will be suitably die-cut and scored by the fabricator, and it will usually then be formed into a tubular structure by folding at the score lines 31a and 31c .and forming a manufactures joint to join the top panel 23 and the side panel 29. In the illustrated embodiment, a taped joint 35 is depicted; however, any suitable type of manufacturers joint may be employed. The container in this flat condition with the manufacturers joint formed is referred to as being in knocked down condition. The containers are then shipped in knocked down condition to the plant of the sink manufacturer who will set up the container when ready to form the package.

The end closure is formed by an upperflap 37, a

lower flap 39, and a pair of side flaps 41. The upper flap 37 and the pair of side flaps 41 are respectively hinged to the top panel 23 and the side panels 27,29 along double score lines, i.e., the transverse score line 33 and an interrupted line 43 to facilitate their being folded flatly against the interior surfaces of the body section panels, although a single score line could be employed. The lower flap is hinged along the transverse score line 33 and contains a parallel'score line 45 spaced to define a short step panel 47 which accommodates the thickness of the sink flange 15 as well as one or more thicknesses of corrugated fiberboard, as hereinafter explained.

It is believed that the end closure construction will be most easily. understood by describing the four closure flaps in the general sequence in which they are closed in order to complete the closure of the package. Accordingly, the following description is set forth in that manner. I

The lower closure flap 39 is cut to provide an irregular shaped aperture 49 and includes a first or main panel 51 which is hinged along the score line 45 to the step panel 47. The opposite edge of the main panel 51 is contoured by the irregular aperture 49 to register with the shape of the transversely extending wall surface of the sink which it generally abuts in its folded condition. More specifically, this edge of the main score lines 57 to the main panel 51 is a second panel portion whcih is split generally in half along a central line 59. Each of the halves is divided into a pair of reinforcing subpanels 61a and 61b which are foldable upon each other along short, parallel slit score lines 63. Lying generally within the region of the irregular aperture 49 and hinged to the first panel by a pair of short double-scored hinges 65 is a narrow reinforcing pad 67.

In forming the package, the body portion of the container 11 is first squared, and then the sink 13 is inserted through either end. The dimensions of the bottom panel 25 is preferably such that it slightly exceeds the dimensions of the rectangular flange 15 of the sink in both directions, so that, in the completed package,

folded. The height of the hinged inner panels 71 is such that, as they are folded into the opening of the main body portion of the container 11, their lower edges slide along the upper surface of the lower flap main panel 51 and thus press the flap firmly against the sink flange. As the outer panels 73 are swung into position, the depending locking tabs 77 snap into the recess 69 provided between the end wall 17 of the sink bowl and the offset edge portion 55 of the lower flap, locking the side flaps in closed position. Because ofthe proportioning of the outer panels 73, the free vertical edges of the panels abut each other when both side flaps 41 are closed and provide a barrier extending completely across the container opening, except' for the access openings provided by the cut-outs 75.

The upper closure flap 37 extends substantially the full length of the container opening and has a subpanel 81 hinged by the double score lines to the top panel 23 time container lull-9Q W l i l,

adhesive, staples or ancillary fasterners of any kind; but it also provides, as an integral part thereof, retainers for positioning the flanged sink centrally within the container. Whereas previously separate cushioning and centering packing forms have been employed to anchor such an article within a corrugated box, these functions are fulfilled by the novel design of the end closure flaps. The illustrated end closure not only locks the perimeter flange of the sink against one interior surface of the container, but it securely fits about the contour of the end of the sink bowl centering it within the package and anchoring it against movement in any direction once the end closure is locked in closed position.

Although the invention has been described with regard to one illustrated embodiment, it should be understood that modifications and changes as would be obvious to one having the ordinary skill in the art may be made without departing from the scope of the invention which is defined by the claims appended hereto.

Various of the features of the invention are set forth in the following claims.

What is claimed is:

1. A partially folded paperboard container blank for packaging a flanged article having a surface extending transversely from the flange thereof, which blank comprises a tubular body section proportioned to receive the flanged article and having top and bottom panels and a pair of side panels,

end closures at each end of said tubular body section for closing the openings thereinto, at least one of said end closures having upper and lower flaps attached respectively to said top and bottom panels,

one of said flaps being constructed to extend into said body section in overlying relationship to a portion of the flange of the article and having an edge which is shaped to lie in generally abutting relationship with the transverse surface of the article when the closure is completed,

at least one of said side panels extending perpendicular to said top and bottom panels when set up to receive a flanged article, said one side panel having a side flap hinged thereto which forms a part of said one end closure,

said side flap having a first panel adapted to extend into said tubular body section and a second panel hinged thereto for extension toward said other side panel, said second panel having a locking tab located for insertion between said shaped edge of said one flap and the transverse article surface when said one end closure is completed, and

the other of said upper and lower flaps including a subpanel adapted to extend into said body section and a main panel hinged thereto for disposition extending generally transverse to and between said top and bottom panels, said main panel having means for engagement with said one flap to lock said main panel in said transverse disposition.

2. The partially folded blank in accordance with claim 1 wherein said tubular body section is rectangular in cross-section in set up condition and wherein each of said side panels is provided with one of said hinged side flaps, the length of each said side flap second panel being equal to about one-half the length of said rectangular body section opening and said second panels each terminating in vertical edges which abut each other when said one end closure is completed.

3. The partially folded blank in accordance with claim 2 wherein said free end of said main panel terminates in a central locking tab and a pair of hinged tab means flanking said locking tab, said tab means each being adapted to extend inward past one of'said side flaps through an opening between said second panel and said one flap when said one end closure is completed.

4. The partially folded blank in accordance with claim 2 wherein said shaped edge of said one flap contains an offset portion that provides a recess for receiving said side flap locking tabs when said one end closure is completed.

5. A package containing a flanged article, having a surface extending transversely from the flange thereof, within a folded paperboard container blank, which container blank comprises a tubular body section wherein said flanged article is received having top and bottom panels and a pair of side panels and being rectangular in cross section, and

end closures at each end of said body section for closing the openings thereinto,

said end closures having upper and lower flaps attached respectively to said top and bottom panels,

said lower flap extending into said body section in overlying contact with a portion of the underside of said flange of said article and having an edge which lies in generally abutting relationship with the transverse surface of said article, said side panels each having side flaps hinged to ends thereof, each side flap having a first panel extending into said tubular body section and a second panel hinged thereto extending toward said other side panel, each second panel having an upper horizontal edge engaging the interior surface of said top panel and having a lower edge engaging said lower flap,

said upper flap including a subpanel extending into said body section and a main panel hinged thereto extending transverse to and between said top and bottom panels, said main panel having means in engagement with said lower flap to lock said main panel in said transverse disposition whereby said main panel and said side flaps hold said lower flap in tight engagement against the underside of said flange thus locking the upper surface of said flange in contact with the interior surface of said bottom panel.

6. The package in accordance with claim 5 wherein the free end of said main panel terminates in a locking tab having a substantially straight edge, said locking tab being disposed between said shaped edge of said lower flap and the transverse surface of said article.

7. The package in accordance with claim 6 wherein said second panels are disposed between said main panel and said article surface and wherein said main panel has a pair of hinged tab means flanking said locking tab, said tab means each extending inward past one of said side flap second panels through an opening between said second panel and said lower flap.

8. The package in accordance with claim 6 wherein said blank is made from a single sheet of corrugated fiberboard which is formed into said tubular body section by a manufacturers joint, the corrugations being shifting movement thereof, said bottom and top panels being wider and longer than said article flange,

10. The package in accordance with claim 5 wherein said upper flap extends substantially the full width of said top panel and wherein said main panel substantially completely closes said body section opening. 

1. A partially folded paperboard container blank for packaging a flanged article having a surface extending transversely from the flange thereof, which blank comprises a tubular body section proportioned to receive the flanged article and having top and bottom panels and a pair of side panels, end closures at each end of said tubular body section for closing the openings thereinto, at least one of said end closures having upper and lower flaps attached respectively to said top and bottom panels, one of said flaps being constructed to extend into said body section in overlying relationship to a portion of the flange of the article and having an edge which is shaped to lie in generally abutting relationship with the transverse surface of the article when the closure is completed, at least one of said side panels extending perpendicular to said top and bottom panels when set up to receive a flanged article, said one side panel having a side flap hinged thereto which forms a part of said one end closure, said side flap having a first panel adapted to extend into said tubular body section and a second panel hinged thereto for extension toward said other side panel, said second panel having a locking tab located for insertion between said shaped edge of said one flap and the transverse article surface when said one end closure is completed, and the other of said upper and lower flaps including a subpanel adapted to extend into said body section and a main panel hinged thereto for disposition extending generally transverse to and between said top and bottom panels, said main panel having means for engagement with said one flap to lock said main panel in said transverse disposition.
 2. The partially folded blank in accordance with claim 1 wherein said tubular body section is rectangular in cross-section in set up condition and wherein each of said side panels is provided with one of said hinged side flaps, the length of each said side flap second panel being equal to about one-half the length of said rectangular body section opening and said second panels each terminating in vertical edges which abut each other when said one end closure is completed.
 3. The partially folded blank in accordance with claim 2 wherein said free end of said main panel terminates in a central locking tab and a pair of hinged tab means flanking said locking tab, said tab means each being adapted to extend inward past one of said side flaps through an opening between said second panel and said one flap when said one end closure is completed.
 4. The partially folded blank in accordance with claim 2 wherein said shaped edge of said one flap contains an offset portion that provides a recess for receiving said side flap locking tabs when said one end closure is completed.
 5. A package containing a flanged article, having a surface extending transversely from the flange thereof, within a folded paperboard container blank, which container blank comprises a tubular body section wherein said flanged article is received having top and bottom panels and a pair of side panels and being rectangular in cross section, and end closures at each end of said body section for closing the openings thereinto, said end closures having upper and lower flaps attached respectively to said top and bottom panels, said lower flap extending into said body section in overlying contact with a portion of the underside of said flange of said article and having an edge which lies in generally abutting relationship with the transverse surface of said article, said side panels each having side flaps hinged to ends thereof, each side flap haVing a first panel extending into said tubular body section and a second panel hinged thereto extending toward said other side panel, each second panel having an upper horizontal edge engaging the interior surface of said top panel and having a lower edge engaging said lower flap, said upper flap including a subpanel extending into said body section and a main panel hinged thereto extending transverse to and between said top and bottom panels, said main panel having means in engagement with said lower flap to lock said main panel in said transverse disposition whereby said main panel and said side flaps hold said lower flap in tight engagement against the underside of said flange thus locking the upper surface of said flange in contact with the interior surface of said bottom panel.
 6. The package in accordance with claim 5 wherein the free end of said main panel terminates in a locking tab having a substantially straight edge, said locking tab being disposed between said shaped edge of said lower flap and the transverse surface of said article.
 7. The package in accordance with claim 6 wherein said second panels are disposed between said main panel and said article surface and wherein said main panel has a pair of hinged tab means flanking said locking tab, said tab means each extending inward past one of said side flap second panels through an opening between said second panel and said lower flap.
 8. The package in accordance with claim 6 wherein said blank is made from a single sheet of corrugated fiberboard which is formed into said tubular body section by a manufacturer''s joint, the corrugations being parallel to the longitudinal hinge lines common to pairs of said body section panels.
 9. The package in accordance with claim 5 wherein said lower flap is cut and scored to provide parts foldable upon itself to thereby provide a three-ply pad which overlies said article flange, portions of which pad are disposed laterally of said article to prevent lateral shifting movement thereof, said bottom and top panels being wider and longer than said article flange.
 10. The package in accordance with claim 5 wherein said upper flap extends substantially the full width of said top panel and wherein said main panel substantially completely closes said body section opening. 